1. The purpose of nonconforming product control
Prevent the unintended use or delivery of substandard products.
2. The method of controlling nonconforming product is
Recognize first and then control.

Control process of unqualified products

1. Identification
Identify unqualified: the basis or standard for judging whether the product is qualified or not.
-Product Standards
—Customer requirements
—Process documents
-Inspection documents
-Template
-Explanation and advice from superiors

2. Identification
Identification of inspection status
—Identifies "pending" or "unqualified".
—Production team: unqualified semi-finished products and raw materials should be marked with "to be processed" or "unqualified".
—The inspector stamps the inspection stamp in the corresponding item column of the random card, process card or "rework order" as a "unqualified" mark.
-Its role is: traceability.
—Final inspection: identification of unqualified brand. Or write down (notify) unqualified phenomena, such as (leakage, cracking, few holes, wrong model, serious indentation, few processes, wrong materials, etc.).

3. Isolation
Requirements: Clear separation from normal qualified products.
—Red plastic tray/material box.
—Special independent defective product rack.
-Divide the unqualified area and place the defective products in the unqualified area.
—The placement of the production area is different from that of other products to show the difference, and then pull it to the repair or rework area as required.
—Regularly arrange personnel to the defective product area for confirmation and quantity registration

4. Record
-Correctly record the type, batch, inspection date, inspection basis, quantity of non-conforming products, and inspection results of the unqualified products on the prescribed inspection report.
—The inspection report is reviewed and approved as required.
-Process:

5. Review
When the amount is large, or when it has a large impact on the company's reputation and funds, it must be reviewed.
(1) Incoming inspection: Disposal opinions signed by the inspection supervisor and above (if necessary, the technical department, production, supply chain, and related departments shall be organized to conduct review).
(2) Process inspection: For batches of unqualified products, the Quality Management Department organizes relevant departments and relevant personnel to review.
(3) Final inspection: The person in charge of the quality control department approves the disposal conclusion, and when necessary, the technical department participates in the review.
6. Disposal
Including the following: selection and use, repair, concession, disposal, corrective and preventive measures.

(1) Disposal of unqualified purchases
—Return
-Concession acceptance
—Require the supplier to take relevant corrective and preventive measures
-Our factory will arrange personnel to review the factory for many consecutive batches of unqualified suppliers and a large number of severely unqualified suppliers, and will strictly inspect the subsequent batches.


(2) Disposal of unqualified products in the process
Generally, there are several ways to dispose of unqualified products: rework and repair, concession acceptance and scrapping.
—The disposal conclusion is: rework and repair, transfer to the rework and repair area for processing or hand over to relevant responsible units and individuals for rework.
—The disposal conclusion is: concession acceptance, the workshop fills in the "concession application form" and is approved by the technical department, and submits technical and quality control measures before concession use.
—The disposal conclusion is: scrap, the inspector informs the department where the scrap is located (workshop or team or contact the corresponding individual), fills in the "scrap form", and the inspector signs the report and submits it to the quality control department for approval. Or larger value, generally more than 2,000 yuan, can be scrapped only with the approval of the company's vice president or general manager. According to the four do not let go principle.

(3) Disposal of final unqualified products
The final inspection unqualified treatment method is generally whole batch rework, and partial rework or partial rework treatment can be selected for batches or even specific defective products.
Pay attention to the final inspection:
—All re-inspection and confirmation are required after rework.
-Make corresponding records.
-Release only after being qualified.
-And strengthen the management of identifiability.
—According to ISO requirements, concession products in defective finished products require customer consent (written consent or approval)

3 How to prevent the occurrence of substandard products

1. How to prevent the production of unqualified products: employees, technicians
People: People are the first resource of an enterprise, especially front-line personnel.
(1) The quality awareness, technical level, product proficiency, cultural quality, physical fitness, working attitude, and whether the operation is performed according to the correct process documents affect the product quality.
(2) Management content: clarify job responsibilities, provide necessary training, ideas to satisfy staff's ability to hold the job, and encourage staff to participate in improvement.
(3) Requirements for people: First, they must have a strong sense of responsibility and good professional ethics.
(4) Requirements for people: understand the basic knowledge of the formation and change of product quality characteristics.
(5) Requirements for people: personnel in key positions should focus on training and work with certificates.
(6) Requirements for people: Improve quality awareness and ideas.

2. How to prevent the production of unqualified products: inspector
Inspection is the first-line quality control personnel. Play an important role in avoiding or reducing product batch failures.
(1) First of all, quality inspectors must have a good sense of professionalism, sense of responsibility, dedication and love of the factory and other professional ethics.
(2) Have a certain degree of education, high product knowledge and rich work experience.
(3) Strong analytical and judgment skills are required.
(4) Carry out inspection in strict accordance with requirements (standards, processes, drawings).
(5) Manage the unqualified according to the system.
(6) Grasp the quality dynamics and improve the inspection system.
(7) Strong ability in quality statistics work, able to use and maintain the management of measuring tools and testing instruments.

3. How to prevent the production of unqualified products: equipment maintenance

Note: The accuracy retention, stability and performance reliability of mechanical equipment will directly affect the fluctuation range of the quality characteristics of processed products.
Daily maintenance: lubrication maintenance (five fixed)
Fixed point: According to the specified location, lubrication point, check point on the lubrication chart, add oil, change oil, etc.
Quality: to ensure the variety, brand and quality requirements of the oil required for lubricating parts
Quantitative: daily lubrication and lubrication of each lubrication part according to the specified quantity
Regularly: add oil at the specified time for lubrication
Appointment: Require specialized personnel (equipment operators or maintenance personnel) to refuel, clean and change oil, etc.

Secondary maintenance: to be done together with equipment operators and maintenance personnel. Maintenance content:
1) Comprehensive cleaning and cleaning equipment related accessories and devices
2) Disassemble and inspect the local and key parts of the equipment to completely remove the oil
3) Check the wear of the equipment, replace auxiliary parts, adjust or stabilize the loose parts

Three-level maintenance (special maintenance): completed by maintenance or professionals, maintenance content:
1) Check and repair the equipment as a whole or part of disassembly
2) Clean the important parts of the equipment and change the oil
3) Repair or replace wearing parts
4) Check, adjust, repair accuracy and correct level

Handling of defects after equipment inspection
Treatment of equipment: 1) Repair or troubleshoot by yourself, and the team leader will handle it. 2) Fill in the "equipment maintenance application" and report to the maintenance department after confirmation by the supervisor
Treatment of products: products produced with poor equipment must be re-inspected or evaluated to prevent defective products or quality accidents

4. How to prevent the occurrence of non-conforming products: management of operating methods
Core: The selection and determination of process methods and maintenance methods, and process discipline management.
Work method management: work instructions, control of abnormal work
The main points of the preparation of the work instruction: 1) Production process flow chart: write out all the production process flow charts and sub-process flow charts, highlight key and important processes, indicate production conditions and control requirements; when the process changes, the process Figure to be revised. 2) Process operation instructions: including content: process name, applicable products, equipment/tools used, materials used, operation steps, control points, production safety precautions, self-inspection content. Compilation points: concise and clear, prominent points, diagrammatic
Management of work instructions: preparation, use control, classification, establishment of a list, modification, invalidation, storage, etc.

5. How to prevent the occurrence of unqualified products: control of abnormal operations
Abnormal operation control (4M change)
Exception: changes in personnel, equipment, materials, and process methods
1) Personnel change: implement training for personnel according to the requirements of the work instruction until they are qualified
2) Equipment change: confirm and inspect the first product, and then proceed to small batch and mass production only after being qualified
3) Material changes: modify the work instructions or process parameter control requirements; carry out trial production; consider the deployment and use of old materials; scrap treatment of unusable old materials
4) Change of process method: revise work instructions, train staff

6. How to prevent the occurrence of substandard products: 5S optimizes the environment and enhances the market
7. How to prevent the occurrence of unqualified products: three inspections, three presses, three autonomy
8. How to prevent the occurrence of unqualified products: other